Backpack Panel With Tunnel Mesh Padding Structure

ABSTRACT

A back panel for a backpack or other luggage designed to be carried on a user&#39;s back with built-in pockets for receiving foam or 3D printed padding is disclosed herein. The back panel includes spacer areas comprised of multiple layers of material affixed to one another and pocket areas that are spaced from one another by the spacer areas. At least a top-most layer of the back panel is composed of a mesh material, and is detached from the other layers within the pocket areas. The back panel is cut from a combination material made from fibers that are woven or knitted together on a single machine, or is 3D printed, with all of the pockets, channels, or tunnels built in.

CROSS REFERENCES TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Patent Application No. 63/150,531, the disclosure of which is hereby incorporated by reference in its entirety herein.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a backpack, rucksack, fanny pack, or other luggage carried on a user's back, with a back panel having a tunnel mesh padding structure that helps to ensure optimized fit and comfort.

Description of the Related Art

The prior art discloses various backpacks and carrying structures with padding intended to protect and support a wearer's back during use. As shown in FIG. 1, these prior art structures involve multiple parts and materials, including different foams, spacers, meshes, and fabrics, that must be connected to one another and to the carrying structure. This poses a major challenge for assembly in an efficient and durable manner, as connecting spacer fabrics with other spacer fabrics and/or spun textiles can be error-prone and requires the use of resins, glues, plastic or metal attachments, multiple sewing steps, and in some circumstances welding. Therefore, there is a need for an improved support structure for backpacks and other carrying devices that is efficient to assemble.

BRIEF SUMMARY OF THE INVENTION

One aspect of the present invention is a simplified back panel for use with a backpack, fanny pack, or similar carrying device with mesh layers arranged to easily incorporate padding into said carrying device. The back panel comprises mesh layers that are woven or knitted together on a single machine, or 3D printed, to form a single piece with pockets, channels, or tunnels, which can then be filled by foam or 3D printed inserts and/or rigid support panels. The panel can then be affixed to or built into the rear surface of a backpack or other carrying device. In some embodiments, a region of the panel without padding aligns with a least a portion of the user's spine, and at least one channel is disposed vertically on either side of the spinal portion to allow for inclusion of a support material such as foam. In other, waist-centered embodiments, such as in fanny packs, one or more channels may extend perpendicular to the spine and support may be aligned at the center to support lumbar region of the spine. These structures require fewer work steps and less sewing to achieve proper support and comfort for the user. They also require fewer materials in the construction and assembly of the product, reducing or eliminating the need for sewing thread, plastic parts, adhesives, and resins.

Another aspect of the present invention is a backpack comprising a back panel comprising a first elongated pocket, a second elongated pocket, and a spacer area disposed between the first elongated pocket and the second elongated pocket, first and second elongated foam, lattice, or 3D printed inserts, and first and second elongated support inserts, wherein each of the first elongated foam, lattice, or 3D printed insert and the first elongated support insert is disposed within the first elongated pocket, and wherein each of the second elongated foam, lattice, or 3D printed insert and the second elongated support insert is disposed within the second elongated pocket. In some embodiments, the back panel may be composed of a multi-layer material, which may be manufactured using a single machine. In other embodiments, at least one of the first and second elongated pockets may be vertically aligned. In still other embodiments, the spacer layer may comprise at least three layers of fabric affixed to one another, and each of the first and second elongated pockets may comprise a base layer spaced from a mesh layer, which may comprise recycled fibers.

Yet another aspect of the present invention is a back panel for luggage carried on a user's back, the back panel comprising a first spacer area comprising a first layer of fabric, a second layer of fabric, and a third layer of fabric, each of which is affixed to the other layers of fabric, and a first pocket area comprising the first layer and a mesh layer, wherein at least a portion of the mesh upper layer is detached from the first layer, and wherein the at least one spacer area is adjacent to the at least one pocket area. In some embodiments, each of the first spacer area and the first pocket area may extend parallel with one another. In other embodiments, the back panel comprises a second pocket area comprising a first layer and a mesh layer, and the first spacer area may be disposed between the first and second pocket layer.

In a further embodiment, each of the first pocket area, first spacer area, and second pocket area may extend vertically across the back panel and is configured so that the first spacer area aligns with a spine of a user. In another embodiment, the back panel may comprise a first foam, lattice, or 3D printed insert disposed within the first pocket area and a second foam, lattice, or 3D printed insert disposed within the second pocket area. In yet another embodiment, the back panel may further comprise a first support strip disposed within the first pocket area between the first foam, lattice, or 3D printed insert and the first layer and a second support strip disposed within the second pocket area between the second foam, lattice, or 3D printed insert and the first layer. At least one of the first foam or 3D printed insert, second foam or 3D printed insert, first support strip, and second support strip may be composed of recycled material. In another embodiment, each of the first and second support strips may be composed of aluminum alloy

Having briefly described the present invention, the above and further objects, features, and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is an exploded view of a prior art backpack support structure.

FIG. 2 is a front view of the support panel of the present invention.

FIG. 3 is a top perspective view of the embodiment shown in FIG. 2 engaged with padding.

FIG. 4 is a front perspective view of the embodiment shown in FIG. 3 engaged with support boards.

FIG. 5 is an exploded view of a backpack support structure engaged with the embodiment shown in FIG. 4.

FIG. 6 is an assembled view of the embodiment shown in FIG. 5 affixed to a backpack.

FIG. 7 is a first alternative embodiment of the present invention.

FIG. 8 is a second alternative embodiment of the present invention.

FIG. 9 is a third alternative embodiment of the present invention.

FIG. 10 is a fourth alternative embodiment of the present invention.

FIG. 11 is an enlarged view of the embodiment shown in FIG. 10.

FIG. 12 is a side perspective view of a 3D printed lattice insert.

FIG. 13 is a view of the embodiment shown in FIG. 4 engaged with a plurality of lattice inserts shown in FIG. 14.

FIG. 14 is an enlarged view of the circled portion of the embodiment shown in FIG. 15.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to a backpack 10, fanny pack 15, or other type of luggage configured to be carried on a user's back, the entire back panel 20 of which comprises a combination material with built in, elongated pockets that form open channels or tunnels sized to encompass padding and/or rigid support material.

A preferred embodiment of the present invention is shown in FIGS. 2-6. As shown in FIGS. 2, 3, and 4, the back panel 20 has alternating first, spacer areas 22 and second, pocket areas 24 that are aligned with a vertical y-axis of the mesh support fabric 20 and alternate with one another along a horizontal x-axis of the back panel 20. Each spacer area 22 comprises at least three layers of fabric, while each pocket area 24 consists of two layers of fabric. The fabric layers of each spacer area 22 are woven, knitted, or 3D printed together on a single machine to form a unitary, reinforced material with the combined properties of the constituent materials, while the two layers of the pocket area 24 are not, thereby creating an opening between spacer areas 22 located on either side of each pocket area 24. The vertical lengths of the spacer and pocket areas 22, 24 may be infinite. When incorporated into a backpack 10, each spacer area 22 has a first vertical length V₁ and a first horizontal width W₁, and at least one of the pocket areas 24 located between spacer areas 22 has a second vertical length V₂ and a second horizontal width W₂. As shown in the Figures V₁ is approximately equivalent to V₂, and W₁ may be equivalent to, smaller, or larger than W₂.

At least the upper layer 21 of the back panel 20 is a mesh fabric made from one or more textile fibers, including natural fibers (silk, wool, animal hair) and manmade fibers (artificial, synthetic, organic, etc.). The lower layers 23, 25 are more tightly woven or knit, and may be composed of any of the aforementioned materials. The fabrics are selected for breathability, absorbency, and moisture transport to optimized comfort when worn by a user. The use of mesh material as an upper layer 21 lowers the overall weight of the back panel 20, and dry-off is accelerated in areas of the back panel 20 that do not contact the user as a result of their large surface areas.

As shown in FIG. 3, foam strips 30, 32 are inserted in two adjacent pocket areas 24 spaced from each other by a spacer area 22. The foam strips 30, 32 substantially fill each of the pocket areas 24 in which they are placed. The foam of these strips 30, 32 preferably is EVA material, but it may include one or more of the following materials: a foam selected from the group such as EVA, PU, algae, oil, PU, TPU, 3D printed materials, padding from textile fibers such as wool, cotton, and silk, and neoprene. The strips 30 may have one or more cutout sections 31, 33 as shown in FIGS. 7 and 8, and/or a lattice 34 structure, an example of which is shown in FIG. 12. The lattice 34 provides additional breathability and retains its form under pressure. The lattice 34 may be made from any thermoplastic material, such as polyurethane/TPU, and may be 3D printed.

Once the pocket areas are filled with the foam strips 30, 32, rigid strips 40, 42 of a board-like material are inserted into the pocket areas 24 behind the foam strips 30, 32 as shown in FIG. 4 to provide additional support and prevent the foam strips 30, 32 from excessive bending. The material used to create these strips 40, 42 comprises one or more of the following: PE, ABS, TPU, metal alloy, aluminum, plastic, wood, bamboo, and/or textile fibers. Other materials may be added to the pocket areas 24 as needed to obtain the desired comfort, stability, or design of the panel 20.

As shown in FIG. 5, this padded combination piece 50 can be (but is not required to be) affixed to a lining 60 and a frame 70 that is built into the backpack 10, fanny pack 15, or carrying device, as shown in FIGS. 6, 10-11, and 13-14. The back panel 20 can alternatively be attached to the outer envelope of the backpack 10 along the side seam 16, and not be directly connected with the lining 60 or frame 70. Preferably, when assembled into the backpack 10 or carrying device, the spacer area 22 aligns with a user's spine and the pocket areas 24 are disposed on either side of the spacer area 24 so that the foam strips 30, 32 can provide support for the user's back without placing pressure on the spine, as shown in FIG. 6. When assembled into a fanny pack 15, as shown in FIGS. 10 and 11, the spacer and pocket areas 22, 24 extend perpendicular to the user's spine and the foam or 3D printed strip 30 is oriented to fit within the lumbar region of the user's back or along the curve of a user's hip.

The embodiment described above may be further reinforced with one or more beam structures 80, as shown in FIGS. 7-8. Back panel 20 sections are integrated with and anchored to the beams 80 by any means known to a person skilled in the art, such as via pins, hook and loop fasteners, ducktail fasteners. These beams 80 preferably are curved to follow the contours of a human spine. As shown in FIG. 7, a beam 80 may be aligned with a user's spine and be disposed between two pockets 24, or it may be disposed so that a pocket 24 with a foam strip 30 is centered over a user's spinal area as shown in FIG. 8. The beams 80 are made of a rigid material, which may be metal, plastic, or another material with similar properties. In an alternative embodiment, shown in FIG. 9, the beams 90 are not integrated with the back panel 20, which is instead affixed to the beams 90 after they are shaped for stabilization or other purposes. Such beams are traditionally used in backpack construction, and may be made of an aluminum alloy or other such lightweight, resilient material.

The construction of the inventive back panel 20 removes the need for complex manufacturing steps such as sewing, welding, and gluing. It can also be produced in large, uniform sheets with any length dimensions desired by the manufacturer. Sections of the resulting material can be custom cut to fit the dimensions and meet the requirements of whatever backpack or carrying device is being assembled, thereby obviating the need for a specially designed and individually developed back panel (such as the one illustrated in FIG. 1) tailored to a particular backpack. Though the preferred embodiment has the spacer and pocket areas 22, 24 aligned vertically, in alternative embodiments, one or more of the spacer and pocket areas 22, 24 may be aligned diagonally or horizontally.

From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, combinations, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. The section titles included herein also are not intended to be limiting. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims. 

We claim:
 1. A backpack comprising: a back panel comprising a first elongated pocket, a second elongated pocket, and a spacer area disposed between the first elongated pocket and the second elongated pocket; first and second elongated lattice inserts; and first and second elongated support inserts, wherein each of the first elongated lattice insert and the first elongated support insert is disposed within the first elongated pocket, and wherein each of the second elongated lattice insert and the second elongated support insert is disposed within the second elongated pocket.
 2. The backpack of claim 1, wherein the back panel is composed of a multi-layer material.
 3. The backpack of claim 2, wherein the multi-layer material is manufactured using a single machine.
 4. The backpack of claim 1, wherein at least one of the first and second elongated pockets is vertically aligned.
 5. The backpack of claim 1, wherein the spacer layer comprises at least three layers of fabric affixed to one another.
 6. The backpack of claim 5, wherein each of the first and second elongated pockets comprises a base layer spaced from a mesh layer.
 7. The backpack of claim 6, wherein the mesh layer comprises recycled fibers.
 8. A back panel for luggage carried on a user's body, the back panel comprising: a first spacer area comprising a first layer of fabric, a second layer of fabric, and a third layer of fabric, each of which is affixed to the other layers of fabric; and a first pocket area comprising the first layer and a mesh layer, wherein at least a portion of the mesh upper layer is detached from the first layer, and wherein the at least one spacer area is adjacent to the at least one pocket area.
 9. The back panel of claim 8, wherein each of the first spacer area and the first pocket area extends parallel with respect to one another.
 10. The back panel of claim 8, wherein each of the first spacer area and the first pocket area extends at an angle with respect to one another.
 11. The back panel of claim 8, further comprising a second pocket area comprising a first layer and a mesh layer, wherein the first spacer area is disposed between the first and second pocket layer.
 12. The back panel of claim 11, wherein each of the first pocket area, first spacer area, and second pocket area extends vertically across the back panel.
 13. The back panel of claim 11, further comprising a first lattice insert disposed within the first pocket area and a second lattice insert disposed within the second pocket area.
 14. The back panel of claim 13, further comprising a first support strip disposed within the first pocket area between the first lattice insert and the first layer and a second support strip disposed within the second pocket area between the second lattice insert and the first layer.
 14. The back panel of claim 14, wherein at least one of the first lattice insert, second lattice insert, first support strip, and second support strip is composed of recycled material.
 15. The back panel of claim 14, wherein each of the first and second support strips is composed of aluminum alloy.
 16. A piece of luggage comprising: a first back panel composed of a multi-layer material, the first back panel comprising a first spacer area, a second spacer area, and a first pocket area disposed between the first spacer area and second spacer area; a second back panel composed of a multi-layer material, the second back panel comprising a third spacer area, a fourth spacer area, and a second pocket area disposed between the third spacer area and the fourth spacer area; a curved beam; a first support strip disposed within the first pocket area; and a second support strip disposed within the second pocket area, wherein the second spacer area is affixed to the curved beam, and wherein the third spacer area is affixed to the curved beam.
 17. The piece of luggage of claim 16, wherein the curved beam is composed of a rigid material selected from the group consisting of a metal alloy and plastic.
 18. The piece of luggage of claim 16, wherein at least one of the first support strip and the second support strip comprises a lattice structure.
 19. The piece of luggage of claim 16, wherein at least one of the first support strip and the second support strip is composed of a foam material.
 20. The piece of luggage of claim 19, wherein the foam material is selected from the group consisting of EVA, PU, algae, oil, PU, TPU, 3D printed materials, padding from textile fibers such as wool, cotton, and silk, and neoprene. 